ESO engine machining

Discussion in 'A Work In Progress' started by kadora, Oct 1, 2016.

Help Support HMEM by donating:

  1. Oct 1, 2016 #1

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Hello engine enthusiasts.

    Winter is coming so i have more time for engines now.
    I have decided to machine another ESO engine so
    I would like to show you machining this engine step by step.
    I am going to start with crank case casting.
    This lost wax casting is crankcase and cylinder in one body.
    picture of blank casting

    2016-09-30-1998.jpg
     
    ICEpeter and michael-au like this.
  2. Oct 1, 2016 #2

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Next step is easy to do but very important is to
    locate casting in vice correctly because all next
    machining operations will be depend on this surface.
    So first pic. casting in vice , second pic. checking height of all four
    corners of the top fin .
    Last pic. surface milling.

    2016-09-30-2001.jpg

    2016-09-30-2003.jpg

    2016-09-30-2004.jpg
     
    ICEpeter and michael-au like this.
  3. Oct 1, 2016 #3

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Now centering and boring the the hole for liner.

    2016-09-30-2006.jpg

    2016-09-30-2009.jpg
     
    ICEpeter and michael-au like this.
  4. Oct 1, 2016 #4

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Milling bottom part of casting

    2016-09-30-2010.jpg
     
    michael-au likes this.
  5. Oct 1, 2016 #5

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Next three steps
    1. milling surface for the front cover //front cover will accommodate
    two ball bearings for crank shaft//
    2. centering hole for crank shaft
    3. boring hole for crank shaft

    2016-09-30-2011.jpg

    2016-09-30-2013.jpg

    7.step.jpg
     
    ICEpeter, michael-au and mayhugh1 like this.
  6. Oct 1, 2016 #6

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Now job for my mini lathe.
    Very easy steps.
    First two pics. show cutting
    the rim for rear cover.
    Third pic. drilling hole for
    timing pulley ball bearing.
    Last pic. shows finished rear part.

    2016-10-01-2015.jpg

    2016-10-01-2017.jpg

    2016-10-01-2019.jpg

    2016-10-01-2020.jpg
     
    Hopper, ICEpeter, michael-au and 3 others like this.
  7. Oct 1, 2016 #7

    Hopper

    Hopper

    Hopper

    Well-Known Member

    Joined:
    Feb 19, 2013
    Messages:
    646
    Likes Received:
    212
    Subscribed. Looks very nice indeed.
     
  8. Oct 1, 2016 #8

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Some additional drilling and casting is done for now.
    Next I will machine front cover - easy process .

    2016-10-01-2022.jpg

    2016-10-01-2024.jpg
     
  9. Oct 2, 2016 #9

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Yesterday I had beautiful evening listening rock songs from 70-ties
    and machining front cover.
    Anyway first pic. shows blank casting .
    Round stem on casting serves as a shaft for comfortable machining.
    On the rest of pictures you can see how easy is to cut rim and holes for
    two ball bearings.

    2016-10-01-2038.jpg

    2016-10-01-2028.jpg

    2016-10-01-2032.jpg

    2016-10-01-2033.jpg

    2016-10-01-2037.jpg
     
    mayhugh1 and akitene like this.
  10. Oct 2, 2016 #10

    Blogwitch

    Blogwitch

    Blogwitch

    Ex Bogstandard HMEM Supporter

    Joined:
    Dec 26, 2008
    Messages:
    3,697
    Likes Received:
    667
    Gender:
    Male
    Occupation:
    Retired Aeronautical Engineer
    Location:
    Crewe, Cheshire, UK
    It is nice to see someone using brazed carbide tooling.

    It seems to have fallen by the wayside over the years, but if good quality ones are used correctly they can really out perform HSS and indexable tooling for very low cost.

    Very nice castings BTW.

    John
     
    H. K. Barrows likes this.
  11. Oct 2, 2016 #11

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    And last simple operations .
    Drilling holes for screws , second picture shows transferring
    holes from front cover to the crank case then cutting threads
    finally checking if everything fits together .
    So front cover is done next crank shaft.

    2016-10-02-2039.jpg

    2016-10-02-2040.jpg

    2016-10-02-2041.jpg

    2016-10-02-2045.jpg
     
    bazmak, ICEpeter, Hopper and 3 others like this.
  12. Oct 3, 2016 #12

    stevehuckss396

    stevehuckss396

    stevehuckss396

    Model Engineer Project of the Month Winner HMEM Supporter

    Joined:
    Nov 19, 2008
    Messages:
    4,101
    Likes Received:
    1,014
    Gender:
    Male
    Occupation:
    Construction
    Location:
    Sterling Heights, MI
    Nice!

    I'll be watching!
     
  13. Oct 3, 2016 #13

    Hopper

    Hopper

    Hopper

    Well-Known Member

    Joined:
    Feb 19, 2013
    Messages:
    646
    Likes Received:
    212
    Progress is looking good. The castings seem to machine very nicely. Some nice grade of aluminium by the look.
    How many CC is this model? What bore and stroke?
     
  14. Oct 3, 2016 #14

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Hello
    Hopper you are right .I bought 70 kg of very good quality aluminium in local
    scrapyard . :D
    Capacity 10 cc, Bore 25 mm, Stroke 20 mm.
     
  15. Oct 3, 2016 #15

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    This is my way of crank shaft machining.
    I know two ways of crank shaft machining.
    First is to machine it from solid bar //this is not job for my hobby lathe//
    second is to assemble it from parts. //my way//

    So on first picture are main shaft and flywheel.
    Here is not need for explanation how to do these parts only diameter and thickness of flywheel is bigger 0.5mm as needed and holes are reamed to H7.

    Second pic. shows hammered bolt between flywheel and shaft.
    Purpose of this bolt is to keep clockwise and anticlockwise torque .

    Third pic. drilling hole through flywheel to the center of main shaft.

    Fourth pic. hammered long bolt to the flywheel. This bolt keeps front and back
    torque of the shaft.

    Fifth pic. machining crank shaft to final dimensions.

    Last pic. cutted thread through long bolt to keep bolt safely in place.

    All joints and bolts are loctite before assembly.
    Any criticism is welcome. //i am still learning//

    2016-10-03-2046.jpg

    2016-10-03-2047.jpg

    2016-10-03-2048.jpg

    2016-10-03-2049.jpg

    2016-10-03-2050.jpg

    2016-10-03-2053.jpg
     
  16. Oct 4, 2016 #16

    Hopper

    Hopper

    Hopper

    Well-Known Member

    Joined:
    Feb 19, 2013
    Messages:
    646
    Likes Received:
    212
    Well it looks like that crank web will never move on its shaft! Should be as strong as the real thing, the way you have done it.
     
    H. K. Barrows likes this.
  17. Oct 4, 2016 #17

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Today only simple part - con rod pin.
    I use for the con rod pin Linear bearing shaft //or guide?//
    because it has ultra hard surface and is grinded to high precision diameter.
    Disadvantage of this linear shaft is impossibility to drill a hole through
    shaft so the only way how to fasten pin to the flywheel is welding.
    1. pic. cut pin //with angle grinder//
    2. pic. pin glued to the flywheel.
    3. pic. aluminium sleeve - to sink heat from the pin during welding process.
    //Sleeve should be more massive but i do not have suitable AL piece right now.//
    Tomorrow welding.

    2016-10-04-2054.jpg

    2016-10-04-2055.jpg

    2016-10-04-2056.jpg
     
    michael-au, mayhugh1 and akitene like this.
  18. Oct 5, 2016 #18

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Hello
    Crank is done.
    1. pic. welded pin //pin is not overheated//
    2. pic. checking if pin is in line with main shaft.
    3. pic. crank assembly - see spacer between ball bearings.
    My conclusion is that this way of crank shaft machining
    is not so precise as machining it from bar but there
    is possibility to use very hard materials for main shaft and
    con rod pin without quenching .

    2016-10-05-2059.jpg

    2016-10-05-2060.jpg

    2016-10-05-2062.jpg
     
    Last edited: Oct 5, 2016
    ICEpeter and michael-au like this.
  19. Oct 6, 2016 #19

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    Today housing for teeth pulley shaft ball bearing .
    1. pic. ball bearing in the housing.
    2. pic. housing pressed to the casting.

    2016-10-06-2063.jpg

    2016-10-06-2064.jpg
     
    michael-au likes this.
  20. Oct 9, 2016 #20

    kadora

    kadora

    kadora

    Project of the Month Winner!!! Project of the Month Winner HMEM Supporter

    Joined:
    Jul 1, 2012
    Messages:
    433
    Likes Received:
    315
    So time to machine rear cover.
    This part holds only one ball bearing so
    machining is easy.
    1. pic. blank casting
    2. pic. cutting rim and drilling hole for ball bearing housing.
    3. pic. ball bearing assembled in housing then pressed into casting.
    4. pic. copy holes from cover to the crank case + cutting threads
    5. pic. liner before pushing into cylinder.
    I use factory made liner //ASP RC engine spare part//
    because this liner has hard chrome plating on inner side.
    This hard plating I am not able to do at home:(

    2016-10-08-2071.jpg

    2016-10-08-2072.jpg

    2016-10-08-2073.jpg

    2016-10-09-2074.jpg

    2016-10-09-2080.jpg
     
    michael-au likes this.

Share This Page